A.Contributing editor Michael Byrne,
moderator of the JLC Online tile forum and an industry
consultant in Los Olivos, Calif., responds: I prefer
traditional mortar-bed construction for both floors and walls
because it allows me to build showers with features like
benches and curved corners. However, that doesn't mean it's the
best method for everybody: Shower surrounds built with
backerboard substrates are perfectly serviceable, whereas in my
consulting work I've seen thousands of mortar-bed shower stalls
that have failed.
The most important elements of a good installation —
regardless of method — are the placement of the
waterproofing, the selection of materials, and the quality of
workmanship.
To eliminate most of the absorption problems associated with
both mortar-bed and backerboard installations, install a sheet
or trowel-applied waterproofing membrane on the surface of the
setting bed (see illustration, right). This helps isolate the
porous setting-bed materials, preventing them from absorbing
moisture and germs.
Continuous surface-applied waterproofing also simplifies the
process of joining tile to bathtubs and preformed shower
receptors.
Most backerboard manufacturers recognize surface-applied
materials and methods and accept them in lieu of traditional
behind-the-board plastic film or felt-paper membranes —
which, after all, get punctured by the fasteners used to attach
the backerboard to the framing. Surface-applied waterproofing
seals all these fastener penetrations.
When building a mortar-bed shower wall, I first install
horizontally oriented layers of felt paper laminated to a
drywall base with a uniform layer of cold-patch sealing
asphalt. This should not be confused with the waterproofing
layer on the surface: The asphalt and felt-paper combination is
required as a cleavage membrane to prevent excess moisture from
wicking out of the fresh mortar and being absorbed by the
drywall. After I float the mortar bed and allow it to cure, I
still cover the entire surface with either a sheet or
trowel-applied system, or a combination of both.
Tile selection is also important. Absorbent, textured, and
grainy ceramic and stone tiles can hold considerable amounts of
water, as well as dirt, oil, germs, and bacteria — all of
which are part of the shower environment and promote mold
growth. So for hygienic reasons steer your clients toward
impervious or vitreous tiles, or stone tiles with similar
properties. The coarse surface texture on some porcelain tiles
— though ideal for slip resistance — makes them,
too, a poor choice for shower-wall use.
The installation materials also should be as impervious as
possible, to minimize absorption and saturation. Add
high-quality latex additives to regular thinset mortar or
grout, or use high-performance polymer-modified thinsets and
grouts that need only water for activation. These materials
absorb and transmit less moisture than regular mixes.
Finally, remember that there's no quick fix for poor
workmanship. An unusually high percentage of shower-stall
failures occur because the installer did not follow specific
manufacturer's instructions or ANSI A108 tile industry
standards. Among the most common problems are improper slope in
the mortar-bed floor; missing movement joints; poor thinset
mixing techniques; inadequate adhesive; lack of sun shields,
which protect mortar and grout from the sun's rays; poorly
compacted grout; the use of too much water to clean grout; and
inadequately cured materials. Another common error is allowing
foot traffic on curing materials. Even when the best materials
are used, any one of these installation errors can result in
failure.